Reservoir for urea solution and method for manufacturing such a reservoir

ABSTRACT

A reservoir or container for a urea solution that includes an upper shell having at least one upper pillar-type structure, a lower shell having at least one lower pillar-type structure spatially arranged opposite to and connected to the at least one upper pillar-type structure to define an internal container volume to receive the urea solution, and a heater in the internal container volume to control the temperature of the urea solution. The at least one lower pillar-type structure is arranged adjacent to the heater.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority 35 U.S.C. §119 to European Patent Publication No. EP13187089.1 (filed on Oct. 2, 2013), which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

Embodiments relate to a reservoir or container for a urea solution, comprising an upper shell, a lower shell and a heater designed (structurally and/or operationally) to control the temperature of the urea solution, and to a method for producing a container of this kind.

BACKGROUND

Conventionally, containers for a urea solution have reinforcing ribs in the upper shell and in the lower shell, the reinforcing ribs extending longitudinally or transversely to the bottom surface or covering surface and being intended to prevent sagging of these surfaces of the container.

This has the disadvantage, however, that it is not possible to draw the entire quantity of liquid out of the container.

FIG. 1 illustrates a sectional view of a container 1 for urea solutions D, as conventionally known. The bottom of the lower shell 3 and the covering surface of the top shell 2 have reinforcing ribs 4, 5. With the bottom of the lower shell 3, the reinforcing ribs 5 of the lower shell form small receptacles, making it impossible to remove the residual quantity B when emptying the container.

German Patent Publication No. DE3213070A1 discloses a fuel tank which has beads which start from the mutually opposite main walls and project into the interior of the tank, and which touch one another and thus form an internal wall.

German Patent Publication No. DE19627741A1 describes a fuel tank, wherein spacers which enter into abutment are provided in the fuel tank between the upper end wall and the bottom in order to maintain a precise spacing.

SUMMARY

In accordance with embodiments, an enhanced container is provided having a high stiffness and in which substantially all the liquid in the tank may be used,

In accordance with embodiments, a method for producing a container having a high stiffness and in which substantially all the liquid in the tank may be used.

In accordance with embodiments, a container for a urea solution, includes at least one of the following: an upper shell having at least one upper pillar-type structure, a lower shell having at least one lower pillar-type structure spatially arranged opposite to and permanently connected to the at least one upper pillar-type structure to thereby join the upper shell and the lower shell, and a heater designed to control the temperature of the urea solution, wherein the at least one lower pillar-type structure is spatially arranged in a region of the heater.

Containers in accordance with embodiments may preferably be arranged in motor vehicles, in which the urea solution may be fed to a catalyst for the purpose of purifying the exhaust gas.

In accordance with embodiments, a plurality of upper pillar-type structures and a plurality of lower pillar-type structures may be provided to structurally reinforce the container. The pillar-type structures are designed and arranged in the upper shell and lower shell in such a way that sagging of the bottom of the lower shell or the covering surface of the top shell is reduced to a minimum.

In accordance with embodiments, the heater is provided since the urea solution may begin to freeze at about −11° C. The heater thereby ensures that the urea solution remains in a liquid state and may be delivered from the container even at low temperatures. Due to the free circulation of heated urea solution in the lower shell without reinforcing ribs, the heating process may be carried out more efficiently. At least one lower pillar-type structure is preferably arranged in the vicinity of the heater, wherein the heater is advantageously accommodated in the lower shell.

Developments of embodiments are indicated in the dependent claims, the description and the attached drawings.

In accordance with embodiments, the upper shell and lower shell are preferably produced from plastic. Plastic has the advantage that it is light and inexpensive. At the same time, the upper shell and the lower shell are preferably produced by injection moulding.

In accordance with embodiments, internal fittings may be moulded into their end position in such containers before injection moulding, making it possible to eliminate what would otherwise be an involved process of installation through an assembly opening, for example.

In accordance with embodiments, the upper shell, the lower shell and the mutually opposite upper pillar-type structures and lower pillar-type structures are connected to one another by welding.

In accordance with embodiments, the upper shell and the lower shell have flanges which run around the outside of the container and which are permanently connected to one another by being heated and subsequently pressed against one another. In this process, the upper pillar-type structure and the lower pillar-type structure are simultaneously welded to one another.

In accordance with embodiments, the heater is arranged centrally in the bottom of the lower shell. The heater thereby ensures in a particularly efficient manner prevention of freezing of the urea solution, even at minus temperatures, since the maximum spacing with respect to the outer wall of the lower shell is less than if the heater were arranged in an edge region of the lower shell. Since the bottom of the lower shell is also heated by the heating, it becomes softer, enabling the bottom to deform, especially when the container is full. For this reason, the lower pillar-type structures are arranged in the region of the heater to specifically counteract this deformation. The lower pillar-type structures are preferably distributed at uniform intervals around the heater in order to enable them to counteract deformation of the bottom of the lower shell in the most efficient manner.

In accordance with embodiments, the heater is preferably integrated into a delivery module. A PTC heating element is preferably used as a heater.

In accordance with embodiments, the upper pillar-type structure and/or the lower pillar-type structure is/are of hollow design. It is thereby possible to achieve a reduction in weight without the structure losing stiffness.

In accordance with embodiments, the upper pillar-type structure and/or lower pillar-type structure is/are formed integrally with the upper shell and/or the lower shell. In this case, the pillar-type structure is formed at the same time during the injection moulding of the upper shell and/or the lower shell.

In accordance with embodiments, a method for producing a container for a urea solution, the method including at least one of the following: providing an upper shell and of a lower shell, wherein the upper shell has at least one upper pillar-type structure and wherein the lower shell has a lower pillar-type structure; and then permanently connecting the upper shell and the lower shell by bringing the at least one upper pillar-type structure into contact with the at least one lower pillar-type structure.

In accordance with embodiments, the upper shell and lower shell, which are produced from plastic by injection moulding, are preferably connected to one another by welding. During this process, the peripheral flanges of the upper shell and lower shell and the contact surfaces of the upper pillar-type structure and the lower pillar-type structure are heated by way of a heating element, with the heating element being removed after the heating process and the heated surfaces of the upper shell being pressed against the heated surfaces of the lower shell and thus being permanently connected to one another. Here, the upper pillar-type structure and the lower pillar-type structure are simultaneously welded to one another.

In accordance with embodiments, the heater is arranged centrally in the bottom of the lower shell, and may be inserted into a pre-mould before the injection moulding of the lower shell. This makes it possible to eliminate an involved subsequent assembly process through an assembly opening.

In accordance with embodiments, a container for a urea solution may include at least one of the following: an upper shell having at least one upper pillar-type structure; a lower shell having at least one lower pillar-type structure spatially arranged opposite to and connected to the at least one upper pillar-type structure to define an internal container volume to receive the urea solution; and a heater in the internal container volume to control the temperature of the urea solution, wherein the at least one lower pillar-type structure is arranged adjacent to the heater.

In accordance with embodiments, a method for producing a container for a urea solution includes at least one of the following: providing an upper shell having at least one upper pillar-type structure and a lower shell having at least one lower pillar-type structure; and then joining the upper shell and the lower shell by connecting the at least one upper pillar-type structure with the at least one lower pillar-type structure to define an internal container volume to receive the urea solution.

In accordance with embodiments, a method for producing a container for a urea solution includes at least one of the following: providing an upper shell having at least one upper pillar-type structure and a lower shell having at least one lower pillar-type structure; and then defining an internal container volume to receive the urea solution by connecting the at least one upper pillar-type structure with the at least one lower pillar-type structure.

In accordance with embodiments, a motor vehicle container for a fluid solution may include at least one of the following: an upper shell having an upper pillar-type structure; a lower shell having a lower pillar-type structure connected to the upper pillar-type structure to define an internal motor vehicle container volume to receive the fluid solution; and a heater in the internal motor vehicle container volume to control the temperature of the fluid solution, wherein the lower pillar-type structure is arranged adjacent to the heater.

DRAWINGS

Embodiments will be illustrated by way of example in the drawings and explained in the description below.

FIG. 1 is a sectioned view of a conventional container.

FIG. 2 is a sectioned view of a conventional container without reinforcement of the bottom of the lower shell.

FIG. 3 is a sectioned view of a container, in accordance with embodiments.

DESCRIPTION

FIG. 2 illustrates a sectioned view of a container 1, which the bottom of the lower shell 3 does not have any reinforcing ribs 5. As a result, the bottom of the lower shell 3 may develop a sag A, as illustrated by the dashed line, especially when the container 1 is full and the heater 6 is switched on, with the result that, in certain circumstances, it may not be possible to maintain a legally required ground clearance on motor vehicles if the container 1 is arranged on the underside of a motor vehicle.

In accordance with embodiments, FIG. 3 illustrates a container 1, such as for example, a motor vehicle, which, on one hand, achieves the required stiffness of the container 1, while on another hand makes possible the removal of essentially all of the urea solution D therefrom. This is due to the fact the container 1 includes an upper shell 2 having upper pillar-type structures 7 formed therein and a lower shell 3 having lower pillar-type structures 8 formed therein. Due to the arrangement of the upper pillar-type structures 7 and the lower pillar-type structure 8, there is only a small sag A at the lower shell 3. The upper shell 2 and the lower shell 3 as well as the upper pillar-type structure 7 and lower pillar-type structure 8 are in substantially the same welding plane C.

A heater 6 may be provided at the lower shell 3 to control the temperature of the urea solution D. In this way, it is ensured that the urea solution D remains in a liquid state and may be delivered from the container 1, even at low temperatures. The heater 6 is arranged centrally in the bottom of the lower shell 3, which enables an efficient manner of preventing freezing of the urea solution D, even at minus temperatures. This is due to the fact the maximum spacing with respect to the outer wall of the lower shell 3 is less than if the heater 6 were arranged in an edge region of the lower shell 3. Since the bottom of the lower shell 3 is also heated by the heater 6, it becomes softer, thereby enabling the bottom to deform, especially when the container 6 is full. For this reason, the lower pillar-type structures 8 may be spatially arranged adjacent to or otherwise in the region of the heater 6 to specifically counteract deformation of the bottom of the lower shell 3. The lower pillar-type structures 8 may be distributed at uniform intervals around the heater 6 in order to enable them to counteract deformation of the bottom of the lower shell 3 in the most efficient manner.

The term “coupled” or “connected” may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical or other connections. In addition, the terms “first,” “second,” etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless other-wise indicated.

Those skilled in the art will appreciate from the foregoing description that the broad techniques of the embodiments may be implemented in a variety of forms. Therefore, while the embodiments have been described in connection with particular examples thereof, the true scope of the embodiments should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

LIST OF REFERENCE SYMBOLS

-   1 container -   2 upper shell -   3 lower shell -   4 reinforcing ribs -   5 reinforcing ribs -   6 heater -   7 upper pillar-type structure -   8 lower pillar-type structure -   A sag -   B residual quantity -   C welding plane -   D urea solution 

What is claimed is:
 1. A container for a urea solution, the container comprising: an upper shell having at least one upper pillar-type structure; a lower shell having at least one lower pillar-type structure spatially arranged opposite to and connected to the at least one upper pillar-type structure to define an internal container volume to receive the urea solution; and a heater in the internal container volume to control the temperature of the urea solution, wherein the at least one lower pillar-type structure is arranged adjacent to the heater.
 2. The container of claim 1, wherein the upper shell and the lower shell are composed of plastic.
 3. The container of claim 1, wherein the upper shell and the lower shell are comprise of by injection moulded plastic.
 4. The container of claim 1, wherein the upper shell and the lower shell are connected to one another by welding.
 5. The container of claim 1, wherein the at least one upper pillar-type structure and the at least one lower pillar-type structure are connected to one another by welding.
 6. The container of claim 1, wherein the heater is arranged centrally at the bottom of the lower shell.
 7. The container of claim 1, wherein the at least one upper pillar-type structure and the at least one lower pillar-type structure are of hollow design.
 8. The container of claim 1, wherein the at least one upper pillar-type structure is of hollow design.
 9. The container of claim 1, wherein the at least one lower pillar-type structure is of hollow design.
 10. The container of claim 1, wherein: the at least one upper pillar-type structure is formed integrally with the upper shell; and the at least one lower pillar-type structure is formed integrally with the lower shell.
 11. The container of claim 1, wherein the at least one upper pillar-type structure is formed integrally with the upper shell.
 12. The container of claim 1, wherein the at least one lower pillar-type structure is formed integrally with the lower shell.
 13. A method for producing a container for a urea solution, the method comprising: providing an upper shell having at least one upper pillar-type structure and a lower shell having at least one lower pillar-type structure; and then joining the upper shell and the lower shell by connecting the at least one upper pillar-type structure with the at least one lower pillar-type structure to define an internal container volume to receive the urea solution.
 14. The method of claim 13, wherein providing the upper shell and the lower shell comprises injection moulding a plastic, respectively.
 15. The method of claim 13, wherein joining the upper shell and the lower shell comprises permanently connecting the at least one upper pillar-type structure with the at least one lower pillar-type structure by welding.
 16. The method of claim 13, further comprising arranging a heater centrally at the bottom of the lower shell.
 17. A motor vehicle container for a fluid solution, the motor vehicle container comprising: an upper shell having an upper pillar-type structure; a lower shell having a lower pillar-type structure connected to the upper pillar-type structure to define an internal motor vehicle container volume to receive the fluid solution; and a heater in the internal motor vehicle container volume to control the temperature of the fluid solution, wherein the lower pillar-type structure is arranged adjacent to the heater.
 18. The motor vehicle container of claim 17, wherein the upper shell and the lower shell are composed of plastic.
 19. The motor vehicle container of claim 17, wherein the heater is arranged centrally at the bottom of the lower shell.
 20. The container of claim 17, wherein at least one of the at least one upper pillar-type structure is formed integrally with the upper shell, and the at least one lower pillar-type structure is formed integrally with the lower shell. 